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REVISED PAGES
T h e I ro n C a r b o n S ys t e m
Of all binary alloy systems, the one that is possibly the most important is that
for iron and carbon. Both steels and cast irons, primary structural materials in
every technologically advanced culture, are essentially ironcarbon alloys. This
section is devoted to a study of the phase diagram for this system and the development of several of the possible microstructures. The relationships among
heat treatment, microstructure, and mechanical properties are explored in Chapters 10 and 11.
ferrite
austenite
Composition (at% C)
1600
10
15
20
25
1538C
1493C
L
1400
2500
"+L
1394C
1147C
2.14
", Austenite
4.30
2000
1000
" + Fe3C
912C
800
Temperature (F)
Temperature (C)
1200
1500
+
"
727C
0.76
0.022
600
+ Fe3C
, Ferrite
Cementite (Fe3C)
400
0
(Fe)
3
4
Composition (wt% C)
1000
6.70
Figure 9.24 The ironiron carbide phase diagram. [Adapted from Binary Alloy Phase
Diagrams, 2nd edition, Vol. 1, T. B. Massalski (Editor-in-Chief), 1990. Reprinted by
permission of ASM International, Materials Park, OH.]
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(a)
cementite
(b)
melts at 15388C (28008F). All these changes are apparent along the left vertical axis
of the phase diagram.1
The composition axis in Figure 9.24 extends only to 6.70 wt% C; at this concentration the intermediate compound iron carbide, or cementite (Fe3C), is formed, which
is represented by a vertical line on the phase diagram. Thus, the ironcarbon system
may be divided into two parts: an iron-rich portion, as in Figure 9.24, and the other
(not shown) for compositions between 6.70 and 100 wt% C (pure graphite). In practice, all steels and cast irons have carbon contents less than 6.70 wt% C; therefore,
we consider only the ironiron carbide system. Figure 9.24 would be more appropriately labeled the FeFe3C phase diagram, since Fe3C is now considered to be a component. Convention and convenience dictate that composition still be expressed in
wt% C rather than wt% Fe3C; 6.70 wt% C corresponds to 100 wt% Fe3C.
Carbon is an interstitial impurity in iron and forms a solid solution with each
of a and d ferrites, and also with austenite, as indicated by the a, d, and g singlephase fields in Figure 9.24. In the BCC a ferrite, only small concentrations of carbon are soluble; the maximum solubility is 0.022 wt% at 7278C (13418F). The limited
solubility is explained by the shape and size of the BCC interstitial positions, which
make it difficult to accommodate the carbon atoms. Even though present in relatively low concentrations, carbon significantly influences the mechanical properties
of ferrite. This particular ironcarbon phase is relatively soft, may be made magnetic at temperatures below 7688C (14148F), and has a density of 7.88 g/cm3. Figure 9.25a is a photomicrograph of a ferrite.
The reader may wonder why no b phase is found on the FeFe3C phase diagram, Figure
9.24 (consistent with the a, b, g, etc. labeling scheme described previously). Early investigators observed that the ferromagnetic behavior of iron disappears at 7688C and attributed this
phenomenon to a phase transformation; the b label was assigned to the high-temperature
phase. Later it was discovered that this loss of magnetism did not result from a phase transformation (see Section 20.6) and, therefore, the presumed b phase did not exist.
REVISED PAGES
cooling
L g 1 Fe3C
heating
(9.18)
the liquid solidifies to form austenite and cementite phases. Of course, subsequent
cooling to room temperature will promote additional phase changes.
It may be noted that a eutectoid invariant point exists at a composition of 0.76 wt%
C and a temperature of 7278C (13418F).This eutectoid reaction may be represented by
Eutectoid reaction
for the iron-iron
carbide system
cooling
(9.19)
or, upon cooling, the solid g phase is transformed into a iron and cementite. (Eutectoid phase transformations were addressed in Section 9.14.) The eutectoid phase
changes described by Equation 9.19 are very important, being fundamental to the
heat treatment of steels, as explained in subsequent discussions.
Ferrous alloys are those in which iron is the prime component, but carbon as
well as other alloying elements may be present. In the classification scheme of ferrous alloys based on carbon content, there are three types: iron, steel, and cast iron.
Commercially pure iron contains less than 0.008 wt% C and, from the phase diagram, is composed almost exclusively of the ferrite phase at room temperature. The
REVISED PAGES
1000
+ Fe3C
900
Temperature (C)
800
+
727C
b
700
600
Fe3C
+ Fe3C
500
x9
400
1.0
Composition (wt% C)
2.0
REVISED PAGES
pearlite
vertical line xx. Initially, the alloy is composed entirely of the austenite phase having
a composition of 0.76 wt% C and corresponding microstructure, also indicated in
Figure 9.26. As the alloy is cooled, there will occur no changes until the eutectoid
temperature (7278C) is reached. Upon crossing this temperature to point b, the
austenite transforms according to Equation 9.19.
The microstructure for this eutectoid steel that is slowly cooled through the
eutectoid temperature consists of alternating layers or lamellae of the two phases
(a and Fe3C) that form simultaneously during the transformation. In this case, the
relative layer thickness is approximately 8 to 1. This microstructure, represented
schematically in Figure 9.26, point b, is called pearlite because it has the appearance of mother of pearl when viewed under the microscope at low magnifications.
Figure 9.27 is a photomicrograph of a eutectoid steel showing the pearlite. The
pearlite exists as grains, often termed colonies; within each colony the layers
are oriented in essentially the same direction, which varies from one colony to
another. The thick light layers are the ferrite phase, and the cementite phase appears as thin lamellae most of which appear dark. Many cementite layers are so
thin that adjacent phase boundaries are so close together that they are indistinguishable at this magnification, and, therefore, appear dark. Mechanically, pearlite
has properties intermediate between the soft, ductile ferrite and the hard, brittle
cementite.
The alternating a and Fe3C layers in pearlite form as such for the same reason that the eutectic structure (Figures 9.13 and 9.14) formsbecause the composition of the parent phase [in this case austenite (0.76 wt% C)] is different
from either of the product phases [ferrite (0.022 wt% C) and cementite (6.7 wt%
C)], and the phase transformation requires that there be a redistribution of the
carbon by diffusion. Figure 9.28 illustrates schematically microstructural changes
that accompany this eutectoid reaction; here the directions of carbon diffusion
are indicated by arrows. Carbon atoms diffuse away from the 0.022 wt% ferrite
regions and to the 6.7 wt% cementite layers, as the pearlite extends from the
grain boundary into the unreacted austenite grain. The layered pearlite forms because carbon atoms need diffuse only minimal distances with the formation of
this structure.
Furthermore, subsequent cooling of the pearlite from point b in Figure 9.26 will
produce relatively insignificant microstructural changes.
Austenite grain
boundary
Ferrite ( )
Austenite
(! )
Ferrite ( )
Austenite
(! )
Ferrite ( )
Cementite
(Fe3C)
Growth direction
of pearlite
Ferrite ( )
Carbon diffusion
Hypoeutectoid Alloys
1100
!
!
!
1000
!
! + Fe3C
M
900
!
c
Temperature (C)
hypoeutectoid alloy
Microstructures for ironiron carbide alloys having other than the eutectoid composition are now explored; these are analogous to the fourth case described in
Section 9.12 and illustrated in Figure 9.16 for the eutectic system. Consider a composition C0 to the left of the eutectoid, between 0.022 and 0.76 wt% C; this is termed
a hypoeutectoid (less than eutectoid) alloy. Cooling an alloy of this composition is
represented by moving down the vertical line yy in Figure 9.29. At about 8758C,
point c, the microstructure will consist entirely of grains of the g phase, as shown
800
d
N
Te
e
O
700
Pearlite
600
Fe3C
Proeutectoid
Eutectoid
+ Fe3C
500
y9
400
0
1.0
C0
Composition (wt% C)
2.0
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proeutectoid ferrite
Figure 9.30
Photomicrograph
of a 0.38 wt% C
steel having a
microstructure
consisting of pearlite
and proeutectoid
ferrite. 6353.
(Photomicrograph
courtesy of Republic
Steel Corporation.)
schematically in the figure. In cooling to point d, about 7758C, which is within the
a 1 g phase region, both these phases will coexist as in the schematic microstructure. Most of the small a particles will form along the original g grain boundaries.
The compositions of both a and g phases may be determined using the appropriate
tie line; these compositions correspond, respectively, to about 0.020 and 0.40 wt% C.
While cooling an alloy through the a 1 g phase region, the composition of the
ferrite phase changes with temperature along the a 2 1a 1 g2 phase boundary, line
MN, becoming slightly richer in carbon. On the other hand, the change in composition of the austenite is more dramatic, proceeding along the 1a 1 g2 2 g boundary,
line MO, as the temperature is reduced.
Cooling from point d to e, just above the eutectoid but still in the a 1 g region,
will produce an increased fraction of the a phase and a microstructure similar to
that also shown: the a particles will have grown larger. At this point, the compositions of the a and g phases are determined by constructing a tie line at the temperature Te; the a phase will contain 0.022 wt% C, while the g phase will be of the
eutectoid composition, 0.76 wt% C.
As the temperature is lowered just below the eutectoid, to point f, all the g
phase that was present at temperature Te (and having the eutectoid composition)
will transform to pearlite, according to the reaction in Equation 9.19. There will be
virtually no change in the a phase that existed at point e in crossing the eutectoid
temperatureit will normally be present as a continuous matrix phase surrounding the isolated pearlite colonies. The microstructure at point f will appear as the
corresponding schematic inset of Figure 9.29. Thus the ferrite phase will be present
both in the pearlite and also as the phase that formed while cooling through the
a 1 g phase region. The ferrite that is present in the pearlite is called eutectoid
ferrite, whereas the other, that formed above Te, is termed proeutectoid (meaning
pre- or before eutectoid) ferrite, as labeled in Figure 9.29. Figure 9.30 is a photomicrograph of a 0.38 wt% C steel; large, white regions correspond to the proeutectoid ferrite. For pearlite, the spacing between the a and Fe3C layers varies
from grain to grain; some of the pearlite appears dark because the many closespaced layers are unresolved at the magnification of the photomicrograph. The
Proeutectoid
ferrite
Pearlite
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Wp 5
T
T1U
C0 2 0.022
C0 2 0.022
5
0.76 2 0.022
0.74
(9.20)
Wa 5
U
T1U
0.76 2 C0
0.76 2 C0
5
0.76 2 0.022
0.74
(9.21)
Of course, fractions of both total a (eutectoid and proeutectoid) and cementite are
determined using the lever rule and a tie line that extends across the entirety of the
a 1 Fe3C phase region, from 0.022 to 6.7 wt% C.
+ Fe3C
Temperature
Figure 9.31 A
portion of the
FeFe3C phase
diagram used in
computations for
relative amounts
of proeutectoid
and pearlite
microconstituents for
hypoeutectoid (C0)
and hypereutectoid
(C1) compositions.
X
+ Fe3C
6.70
0.022 C90
0.76
C91
Composition (wt% C)
P
! + Fe3C
1000
!
!
!
900
Fe3C
Temperature (C)
!
!
800
+!
O
700
i
Pearlite
600
Proeutectoid
Eutectoid Fe3C
Fe3C
500
400
+ Fe3C
z'
0
1.0
2.0
C1
Composition (wt% C)
Hypereutectoid Alloys
hypereutectoid
alloy
proeutectoid
cementite
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Proeutectoid
cementite
Pearlite
wt% C. Thus, for an alloy having composition C1 in Figure 9.31, fractions of pearlite
Wp and proeutectoid cementite WFe3C are determined from the following lever rule
expressions:
6.70 2 C1
6.70 2 C1
X
5
5
Wp 5
(9.22)
V1X
6.70 2 0.76
5.94
and
C1 2 0.76
C1 2 0.76
V
(9.23)
5
5
WFe3C 5
V1X
6.70 2 0.76
5.94
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6.70 2 0.35
5 0.95
6.70 2 0.022
and
WFe3C 5
0.35 2 0.022
5 0.05
6.70 2 0.022
(b) The fractions of proeutectoid ferrite and pearlite are determined by using the lever rule and a tie line that extends only to the eutectoid composition (i.e., Equations 9.20 and 9.21). Or
Wp 5
0.35 2 0.022
5 0.44
0.76 2 0.022
Wa 5
0.76 2 0.35
5 0.56
0.76 2 0.022
and
(c) All ferrite is either as proeutectoid or eutectoid (in the pearlite). Therefore, the sum of these two ferrite fractions will equal the fraction of total ferrite; that is,
Wa 1 Wae 5 Wa
where Wae denotes the fraction of the total alloy that is eutectoid ferrite.Values
for Wa and Wa were determined in parts (a) and (b) as 0.95 and 0.56,
respectively. Therefore,
Wae 5 Wa 2 Wa 5 0.95 2 0.56 5 0.39
Nonequilibrium Cooling
In this discussion on the microstructural development of ironcarbon alloys it has
been assumed that, upon cooling, conditions of metastable equilibrium2 have been
continuously maintained; that is, sufficient time has been allowed at each new temperature for any necessary adjustment in phase compositions and relative amounts
as predicted from the FeFe3C phase diagram. In most situations these cooling rates
are impractically slow and really unnecessary; in fact, on many occasions nonequilibrium conditions are desirable. Two nonequilibrium effects of practical importance
are (1) the occurrence of phase changes or transformations at temperatures other
than those predicted by phase boundary lines on the phase diagram, and (2) the
2
The term metastable equilibrium is used in this discussion inasmuch as Fe3C is only a
metastable compound.
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Mo
1200
2200
Si
2000
1000
1800
Cr
1600
800
1400
Mn
2400
Ti
1200
600
Ni
0
10
12
1000
14
0.8
Ni
0.6
Cr
0.4
Si
Mo
0.2
Ti
Mn
2
4
6
8
10 12 14
Concentration of alloying elements (wt%)